Polymerization catalysts, their production and use

ABSTRACT

The invention generally relates to a catalyst, particularly a metallocene catalyst and catalyst system useful in the polymerization of olefins into a polymer product. Specifically, a catalyst system with (n-PrCp) 2  ZrCl 2  exhibits high catalytic activity.

CROSS-REFERENCE TO RELATED PATENT AND PATENT APPLICATIONS

This patent specification is a continuation-in-part of U.S. application Ser. No. 08/668,868, filed Jun. 24, 1996 allowed and U.S. application Ser. No. 08/726,020 abandoned, filed Oct. 4, 1996, which is a continuation of U.S. application Ser. No. 08/668,868, filed Jun. 24, 1996, which is a continuation of U.S. application Ser. No. 08/284,340, filed Aug. 2, 1994 abandoned, which is a continuation-in-part of U.S. application Ser. No. 08/103,505, filed Aug. 6, 1993 abandoned and U.S. application Ser. No. 07/865,579, filed Apr. 9, 1992 (now U.S. Pat. No. 5,281,679, issued Jan. 25, 1994), and U.S. application Ser. Nos. 08/246,911 and 08/246,914, both filed May 20, 1994, both abandoned and U.S. application Ser. No. 08/190,718, filed Feb. 1, 1994 U.S. Pat. No. 5,359,015, all of which are herein incorporated by reference.

FIELD OF THE INVENTION

This invention relates to catalysts, catalyst systems and to methods for their production and use in olefin polymerization. This invention particularly relates to metallocene catalysts and systems useful for the polymerization and copolymerization of alpha-olefins and to high melt strength polymers and products and applications therefrom.

BACKGROUND OF THE INVENTION

Commercial polyethylenes generally fall into one of two general categories based on their processability and their product properties.

Processability is the ability to predict and economically process and shape a polymer uniformly. Processability involves such elements as thermal stability, how easily the polymer flows, melt strength, and whether or not the extrudate is distortion free. Linear polyethylene (LPE) is more difficult to process than low density polyethylenes (LDPE) because LPE's are not as thermally stable, LPE's require more motor power and produce higher extruder pressures to match the extrusion rate of LDPE's. LPE's also have lower melt strength which, for example, adversely affects bubble stability during blown film extrusion, and they are prone to melt fracture at commercial shear rates. On the other hand, however, LPE's exhibit superior physical properties as compared to LDPE's.

In order to take advantage of the superior physical and mechanical properties of LPE's, expensive antioxidants and processing aids must be added to the polymer, and extrusion equipment must be modified to achieve commercial extrusion rates.

It is common practice in the industry to add low levels of an LDPE to an LPE to increase melt strength, to increase shear sensitivity, i.e., to increase flow at a given horse power; and to reduce the tendency to melt fracture. However, these blends generally have poor mechanical properties as compared with neat LPE.

A second technique to improve the processability of LPE's is to broaden the products' molecular weight distribution (MWD) by blending two or more LPE's with significantly different molecular weights, or by changing to a polymerization catalyst which produces broad MWD. The physical and mechanical properties and the processability of these broader MWD products are generally intermediate between those of narrower LPE components and LDPE/LPE blends with equivalent Mw.

Therefore, a need exists for catalyst which offers the processability of blends but the properties of the linear blend components.

SUMMARY OF THE INVENTION

This invention is directed toward the polymerization of olefins, optionally with a comonomer in the presence of metallocene catalyst to produce a polymer product having a controlled molecular weight distribution, ranging from narrow to broad, a high molecular weight and a narrow composition distribution.

The catalyst of the invention provides for linear polyethylenes and ethylene-α-olefin copolymers with substantially higher melt strength than linear polyethylenes produced with a conventional Ziegler-Natta catalyst or a typical metallocene catalyst. These polyethylenes and copolymers flow in an extruder more easily than their analogs and have superior mechanical properties to polymers produced with post-reactor blending.

In one embodiment the invention provides a catalyst for polymerizing olefins comprising a first component comprising at least one transition metal of Group IV, V or VI and bonded to at least two cyclopentadienyl containing rings, said rings each having at least two substituents bonded to each of said rings in the same position; a second component comprising said transition metal and said cyclopentadienyl containing rings, said rings each having at least two substituents bonded to each of said rings in the same or different position than said substituents of said first component; said substituents of the said first and second components can be the same or different, with the provision that when the substituents of said first and second components are the same, said substituents of said components are bonded to said rings in different positions; and a third component comprising said transition metal bonded to said cyclopentadienyl containing rings where one of said rings is substituted identically as said first component and another of said rings is substituted identically as said second component. In one embodiment the substituents are hydrocarbyl substituents.

The invention further provides for catalyst systems comprising the catalyst component above in combination with a cocatalyst and/or activator for the catalyst. The cocatalyst or activator can be either alumoxane or an ionic activator.

In yet another embodiment the catalyst is supported.

In one embodiment of the invention, there is provided a process for producing polyolefins by contacting olefin monomer, optionally with comonomer in the presence of the catalyst system above

The invention also provides for the production of polymers with high melt strengths that are easily processable through a die when making film. The polymers of the invention are more readily extrudable through a die than their conventional Ziegler-Natta analogs. Further, the invention provides for a film, particularly a blown film, that has a unique combination of physical properties.

DETAILED DESCRIPTION OF THE INVENTION

Introduction

This invention is generally directed toward a catalyst useful for polymerizing and copolymerizing olefins. The polymers produced have unique properties making them easily processable without the need for blending to increase processability.

The catalyst of the invention is classified generally in the field of transition metal catalysis. Over the past few years a new catalyst technology has developed, which provides for the modification and/or control over the properties and characteristics of a polymer. This technology generally involves the use of single-site catalysts to produce a broad range of polymers generally having a narrow molecular weight distribution (NMWD) and a narrow composition distribution (NCD). The art has focused on many types of catalysts and catalyst systems. A catalyst that produces a polymer having both a broad molecular weight distribution (BMWD), a high molecular weight (HMW) and a NCD has gone unknown until now.

Traditionally in the art metallocene catalyst are utilized in their pure form requiring many purification steps. In some instances these pure catalysts are combined together to produce a polymer having a bimodal MWD. This invention provides in one embodiment a method for producing the commercially viable catalyst of the invention in an inexpensive and simple manner.

Catalyst Systems and Methods for Their Production

For the purposes of this patent specification the term "metallocene" is defined to mean two or more cyclopentadienyl containing rings in combination with a transition metal. More particularly, the metallocene of the invention contains two or more substituted rings in combination with a Group IV, V or VI transition metal.

In one embodiment the catalyst for polymerizing olefins of the invention comprises a first component comprising at least one transition metal of Group IV, V or VI and at least two cyclopentadienyl containing rings, said rings each having at least two substituents bonded to each of said rings in the same position; and a second component comprising said transition metal and said rings such that said substituents are bonded to each of said rings in a different position than said substituents of said first component such that said substituents on each of said rings in said second component are in the same position; and a third component comprising said transition metal and said rings such that said substituents are bonded to one of said rings in the same position as said first component and said substituents of another of said rings bonded in the same position as said second component.

In another embodiment, the metallocene catalyst of the invention is represented by the general formula B_(b) (S_(s) R)_(r) MD_(d) A_(a) wherein R is a cyclopentadienyl containing ring, M is a group IV, V or VI transition metal, S is a hydrocarbyl, alkoxy, silyl, siloxy group or a halogen or a two carbon atoms joined together to form a part of a C₄ to C₆ ring; A is a halogen, D is a hydrocarbyl radical, a arylalkyl radical, an alkylidene or a hydrocarboxy radical; and B is a radical bridging two R rings, where B contains a carbon, a germanium, a silicon, a phosphorous or a nitrogen atom or combination thereof; r is 2 to 3, b is 0 to 5; s is 2 to 5; d is 0 to 2; a is 0 to 2; and r+d+a is equal to the oxidation state of M.

In another embodiment the catalyst of the invention is represented by the following formulae:

    (S.sub.1 S.sup.a.sub.x R.sup.a).sub.2 ML.sub.2 ;           a)

and

    (S.sub.1 S.sup.b.sub.x R.sup.b).sub.2 ML.sub.2 ;           b)

and

    (S.sub.1 S.sup.a.sub.x R.sup.a)(S.sub.1 S.sup.b.sub.x R.sup.b)ML.sub.2c)

where S₁ is a hydrocarbyl substituent, S^(a) and S^(b) are the same hydrocarbyl substituent that are either the same or different from S₁ ; R^(a) and R^(b) are a cyclopentadienyl containing ring; M is a transition metal of Group IV, V or VI; L is a halogen and/or hydrocarbyl radical; x is an integer from 2 to 4; S^(a) and S^(b) are bonded to their respective R^(a) and R^(b) in different positions; and where x is 4, S₁ is different from S^(a) and S^(b).

In still yet another embodiment the metallocene catalyst of the invention includes its representative isomers; namely, constitutional isomers, stereoisomers, configurational isomers, geometric isomers, enantiomers and diasteriomers of the metallocene.

Metallocenes selected to have a good comonomer incorporation, hydrogen sensitivity and polymerization activity are preferred. The preferred metallocenes are those metallocenes having two to five substituents on the cyclopentadienyl rings, more preferably two to three substituents and most preferably two substituents. The more preferred metallocenes of the invention include those wherein three of the cyclopentadienyl ring protons are substituted with hydrocarbyl groups, for example:

1)

(i) (1-ethyl-2,4-dimethyl Cp)₂ ZrCl₂ ;

(ii) (1,2-diethyl-4-methyl Cp)₂ ZrCl₂ ;

(iii) (1-ethyl-3,4-dimethyl Cp)₂ ZrCl₂ ;

(iv) (1-ethyl-2,4-dimethyl Cp)(1,2-diethyl4-methyl Cp) ZrCl₂ ;

(v) (1-ethyl-2,4-dimethyl Cp)(1-ethyl-3,4-dimethyl Cp) ZrCl₂ ; and

(vi) (1,2-diethyl-4-methyl Cp)(1-ethyl-3,4-dimethyl Cp) ZrCl₂

2)

(i) (1,2-diethyl-4-methyl Cp)₂ ZrCl₂ ;

(ii) (1,3-diethyl-4-methyl Cp)₂ ZrCl₂ ;

(iii) (1,5-diethyl-4-methyl Cp)₂ ZrCl₂

(iv) (1,2-diethyl-4-methyl Cp)(1,3-diethyl-4-methyl Cp) ZrCl₂ ;

(v) (1,2-diethyl-4-methyl Cp)(1,5-diethyl-4-methyl Cp) ZrCl₂ ; and

(vi) (1,3-diethyl-4-methyl Cp)(1,5-diethyl-4-methyl Cp) ZrCl₂

The most preferred metallocenes of the invention are those wherein two of the cyclopentadienyl ring protons are substituted with hydrocarbyl groups, for example:

1)

(i) (1,2-methyl ethyl Cp)₂ ZrCl₂ ;

(ii) (1,3-methyl ethyl Cp)₂ ZrCl₂ ; and

(iii) (1,2-methyl ethyl Cp)(1,3-methyl ethyl Cp) ZrCl₂

For the purposes of this patent specification all the catalysts of the invention can be represented by the following general designation, for example, this particular catalyst of the invention above is represented by (1,2/1,3-MeEtCp)₂ ZrCl₂, which catalyst description includes 1) (i), (ii) and (iii).

2)

(i) (1,2-methyl ^(n) Propyl Cp)₂ ZrCl₂ ;

(ii) (1,3-methyl ^(n) Propyl Cp)₂ ZrCl₂ ; and

(iii) (1,2-methyl ^(n) Propyl Cp)(1,3-methyl^(n) Propyl Cp) ZrCl₂

3)

(i) (1,2-methyl ^(i) Propyl Cp)₂ ZrCl₂ ;

(ii) (1,3-methyl ^(i) Propyl Cp)₂ ZrCl₂ ; and

(iii) (1,2-methyl ^(i) Propyl Cp)(1,3-methyl ^(i) Propyl Cp) ZrCl₂

4)

(i) (1,2-methyl ^(n) Butyl Cp)₂ ZrCl₂ ;

(ii) (1,3-methyl ^(n) Butyl Cp)₂ ZrCl₂ ; and

(iii) (1,2-methyl ^(n) Butyl Cp)(1,3-methyl^(n) Butyl Cp) ZrCl₂

5)

(i) (1,2-methyl ^(i) Butyl CP)₂ ZrCl₂ ;

(ii) (1,3-methyl ^(i) Butyl Cp)₂ ZrCl₂ ; and

(iii) (1,2-methyl ^(i) Butyl Cp)(1,3-methyl^(i) Butyl Cp) ZrCl₂

In a preferred embodiment, for producing the catalyst of the invention one such method involves 1) reaction of monomeric methyl-cyclopentadiene with either sodium, potassium or an alkyl-lithium, and reacting the product with an appropriate alkyl halide. These steps can be repeated to afford the desired substitution of ring protons with the desired hydrocarbyl radical; 2) the appropriately substituted cyclopentadienyl ligand is then reacted with either sodium, potassium or an alkyl-lithium and the reaction product is reacted with the appropriate transition metal compound denoted by ML₄ previously defined; 3) The product from above is then purified by crystallization and/or sublimation.

In another embodiment, a method for producing the catalyst of the invention involves 1) reacting the reaction product of monomeric cyclopentadiene (R) and sodium, potassium or an alkyl-lithium with an alkyl halide to form a cyclopentadienyl ligand formula (SR) defined. This process can then be repeated to form the desired final S_(s) R ligand previously defined. 2) The desired S_(s) R ligand previously defined is then reacted with sodium, potassium or an alkyl-lithium and the product therefrom is reacted with a transition metal salt of general formula ML₄. 3) The final product is then purified by crystallization and/or sublimation. The above two detailed methods provide for making the preferred catalyst of the invention as a single catalyst. For the purposes of this patent specification, the term "single catalyst" indicates that the three or more component species forming the catalyst of this invention is made simultaneously in one reaction rather than being made individually and then combined.

In one embodiment of the invention the metallocene catalyst of this invention can be used in combination with at least one other metallocene well known in the art to further control the properties of the polymer desired. It is preferred that a ratio of the catalyst of this invention to the other catalyst is preferably 1:19 to 19:1, more preferably 1:3 to 3:1, still more preferably 1:2 to 2:1 and most preferably 1:1.

In another embodiment the three or more components of the catalyst of the invention are each present in an amount greater than 1 mole percent, preferably greater than 2, more preferably greater than 5 and even more preferably greater than 7 and most preferably greater than 10.

In still another embodiment each metallocene component of the invention is made individually by any method known to one of ordinary skill in the art. These individual components can be combined to form the catalyst of the invention.

Exemplary of the development of metallocene catalysts for the polymerization of alpha-olefins is the disclosure of U.S. Pat. Nos. 4,871,705, 4,937,299, 5,017,714, 5,120,867, 5,324,800 and EP-A-0 129 368 published Jul. 26, 1989, all of which are fully incorporated herein by reference. These publications teach the structure of the metallocene catalysts and include alumoxane as the cocatalyst. There are a variety of methods for preparing alumoxane described in U.S. Pat. Nos. 4,665,208, 4,952,540, 5,235,081, 5,103,031, 4,924,018, 5.206,199. Other cocatalysts may be used with metallocenes, such as trialkylaluminum compounds; or ionizing ionic activators or compounds such as tri (n-butyl) ammonium tetra (pentaflurophenyl) boron, which ionize the neutral metallocene compound. Such ionizing compounds may contain an active proton, or some other cation associated with but not coordinated or only loosely coordinated to the remaining ion of the ionizing ionic compound. Such compounds and the like are described in EP-A-0 277 003, EP-A-0 277 004 EP-A-0 520 732, EP-A-0 420 436, PCT International Publication WO 92/00333, WO 94/07928, WO 91/04257 and WO 94/03506 and U.S. Pat. Nos. 5,057,475, 5,096,867, 5,055,438, 5,198,401, 5,227,440, 5,264,405, 5,153,157 and 5,198,401 and are all herein fully incorporated by reference. In additional, the metallocene catalysts useful in this invention can include non-cyclopentadienyl catalyst components, or ancillary ligands such as boroles or carbollides in combination with a transition metal. Additionally it is not beyond the scope of this invention that the catalysts and catalyst systems of the invention could be used in combination with those catalysts and catalyst systems described in U.S. Pat. Nos. 5,064,802, 5,149,819, 5,243,001, 5,239,022, 5,276,208, 5,296,434, 5,321,106 and 5,304,614 and PCT publications WO 93/08221, WO 93/08199 and EP-A-0 578 838, all of which are herein incorporated by reference. All the catalyst systems described above may be, optionally, prepolymerized or used in conjunction with an additive or scavenging component to enhance catalytic productivity, see for example PCT Publication WO 94/07927, incorporated herein by reference.

Combinations of activators are also contemplated by the invention, for example, alumoxane and ionizing activators, see for example, WO 94/07928.

The catalyst in a gas phase process may be supported on any suitable particulate material or porous carrier such as polymeric supports or inorganic oxide for example silica, alumina or both. Methods of supporting the catalyst of this invention are described in U.S. Pat. Nos. 4,808,561, 4,897,455, 4,937,301, 4,937,217, 4,912,075, 5,008,228, 5,086,025, 5,147,949, 5,238,892 and U.S. application Ser. No. 885,170, filed May 18, 1992, all of which are herein incorporated by reference.

Polymerization Process

The polymerization of olefins utilizing the catalyst of the invention can be conducted in a solution, slurry or gas phase. A gas phase polymerization process is preferred. (See for example U.S. Pat. Nos. 4,543,399, 4,588,790, 5,028,670 and U.S. application Ser. No. 053,067, filed Apr. 26, 1993 now U.S. Pat. No. 5,352,749, all of which are herein incorporated by reference.)

The polymerization or copolymerization process of the invention involves the polymerization of one or more cyclic or acyclic alpha-olefin or polyene monomer(s) having from 2 to 20 carbon atoms, preferably 2-15 carbon atoms.

The invention is particularly well suited to the copolymerization reactions involving the polymerization of one or more of the monomers, for example, alpha-olefin monomers of ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicesene and cyclic olefins and styrene. Other monomers can include polar vinyl, diolefins such as dienes, norbornene, norboradiene, acetylene and aldehyde monomers. Preferably the comonomer is an alpha-olefin having from 3 to 15 carbon atoms, more preferably 4 to 12 carbon atoms.

In one embodiment the monomer is polymerized with at least two comonomers to form a terpolymer and the like.

In the preferred embodiment the monomer is ethylene and at least one comonomer of 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene or 1-octene.

In one embodiment of the invention the olefin(s) are prepolymerized in the presence of the catalyst system of the invention prior to the main polymerization, see for example U.S. Pat. Nos. 4,923,833 and 4,921,825 and EP-B-0 279 863, all of which are herein incorporated by reference.

Polymer Properties

The polymer and product properties cited below and in Table 4 were determined in accordance with the following test procedures. Where any of these properties is referenced in the appended product claims, it is to be measured in accordance with the specified test procedure.

    ______________________________________                                         Property           Units   Procedure                                           ______________________________________                                         Melt Indices, Melt Flow Ratios                                                                    dg/min  ASTM D-1238                                           Density g/cc ASTM D-1505                                                       Haze % ASTM D-1003                                                             Gloss @ 45° % ASTM D-2457                                               Tensile @ Yield mPa ASTM D-882                                                 Elongation @ Yield % ASTM D-882                                                Tensile @ Break mPa ASTM D-882                                                 Elongation @ Break % ASTM D-882                                                1% Secant Modulus mPa ASTM D-882                                               Dart Drop Impact g/μm ASTM D-1709                                           Elmendorf Tear Resistance g/μm ASTM D-1922                                  Puncture Force N/μm ASTM D-3763                                             Puncture Energy mJ/μm ASTM D-3763                                           Reblock g ASTM D-3354                                                          Hexane Extractables wt % 21CFR177.1520(d)                                      Melt Strength cN As Described                                                  Molecular Weight amu In the Patent                                             Composition Distribution Breadth Index % Specification                       ______________________________________                                    

Depending on how well the catalyst of the invention incorporates comonomer certain levels of comonomer may yield certain levels of polymer density. For example, highly incorporating catalyst can produce a low density polymer with a low level of comonomer (C_(x)). Similarly, depending on how the catalyst responds to hydrogen, certain levels of melt indices may be obtained. For the preferred alpha-olefin monomer ethylene (C₂), depending on the catalyst, the C_(x) /C₂ ratios is preferably less than about 0.2, more preferably less than about 0.1, and as low as about 0.02 to provide a polymer having a density in the range of from about 0.86 g/cm³ to about 0.97 g/cm³, preferably about 0.88 g/cm³ to about 0.94 g/cm³, more preferably between about 0.90 g/cm³ to about 0.935 g/cm³ and most preferably between about 0.91 g/cm³ to about 0.93 g/cm³.

MWD, or polydispersity, is a well known characteristic of polymers. MWD is generally described as the ratio of the weight average molecular weight (Mw) to the number average molecular weight (Mn). The ratio Mw/Mn can be measured directly by gel permeation chromatography techniques, or indirectly, by measuring the ratio of I₂₁ to I₂ as described in ASTM D-1238-F and ASTM D-1238-E respectively. I₂ is well known in the art as equivalent to Melt Index (MI). I₂₁ is also known as high load melt index (HLMI). MI is inversely proportional to the molecular weight of the polymer (Mw). The MI of the polymers of the invention are generally in the range of about 0.1 dg/min to about 1000 dg/min, preferably about 0.2 dg/min to about 300 dg/min, more preferably about 0.3 to about 200 dg/min and most preferably about 0.5 dg/min to about 100 dg/min.

The ratio of I₂₁ /I₂ is known as the melt index ratio (MIR) and for the purposes of this patent specification the ratio is also defined to be melt flow ratio (MFR). MIR is generally proportional to the MWD.

The MIR of the polymers of this invention are generally in the range of greater than 14 to about 200, preferably about 18 to about 60 and most preferably about 22 to about 45.

Those skilled in the art will appreciate that there are several methods for determining MWD of a polymer sample. For the purposes of this patent specification the molecular weight distribution of a polymer can be determined with a Waters Gel Permeation Chromatograph equipped with Ultrastyrogel columns and a refractive index detector. In this development, the operating temperature of the instrument was set at 145° C., the eluting solvent was trichlorobenzene, and the calibration standards included sixteen polystyrenes of precisely known molecular weight, ranging from a molecular weight of 500 to a molecular weight of 5.2 million, and a polyethylene standard, NBS 1475.

The polymers of the invention as compared to traditional single metallocene polymers have a broad molecular weight distribution. The MWD of the polymers of the invention are in the range of greater than about 2.5 to about greater than 30, preferably in the range of greater than about 3.0 to about 20 and most preferably in the range of about 4 to about 10. In another embodiment the MWD is greater than about 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8 and 3.9.

Another important characteristic of the polymer of the invention is its composition distribution (CD). As is well known to those skilled in the art, the composition distribution of a copolymer relates to the uniformity of distribution of comonomer among the molecules of the copolymer. Metallocene catalysts are known to incorporate comonomer very evenly among the polymer molecules they produce. Thus, copolymers produced from a catalyst system having a single metallocene have a very narrow composition distribution--most of the polymer molecules will have roughly the same comonomer content, and within each molecule the comonomer will be randomly distributed. Conventional Ziegler-Natta catalysts, on the other hand generally yield copolymers having a considerably broader composition distribution. Comonomer inclusion will vary widely among the polymer molecules.

A measure of composition distribution is the "Composition Distribution Breadth Index" ("CDBI"). CDBI is defined as the weight percent of the copolymer molecules having a comonomer content within 50% (that is, 25% on each side) of the median total molar comonomer content. The CDBI of a copolymer is readily determined utilizing well known techniques for isolating individual fractions of a sample of the copolymer. One such technique is Temperature Rising Elution Fraction (TREF), as described in Wild, et al., J. Poly. Sci., Poly. Phys. Ed., vol. 20, p. 441 (1982) and U.S. Pat. No. 5,008,204, which are incorporated herein by reference.

To determine CDBI, a solubility distribution curve is first generated for the copolymer. This may be accomplished using data acquired from the TREF technique described above. This solubility distribution curve is a plot of the weight fraction of the copolymer that is solubilized as a function of temperature. This is converted to a weight fraction versus composition distribution curve. For the purpose of simplifying the correlation of composition with elution temperature all fractions are assumed to have a Mn greater than or equal to 15,000 g/mole, where Mn is the number average molecular weight fraction. Low weight fractions generally represent a trivial portion of the resin of the present invention. The remainder of this description and the appended claims maintain this convention of the number average molecular weight of the fraction.

From the weight fraction versus composition distribution curve the CDBI is determined by establishing what weight percent of the sample has a comonomer content within 25% each side of the median comonomer content. Further details of determining the CDBI of a copolymer are known to those skilled in the art. See, for example, PCT Patent Application WO 93/03093, published Feb. 18, 1993.

Long chain branching can be determined in the ethylene-butene examples of the invention with C13-NMR. Samples are dissolved in deuterated tetrachloroethane at a concentration of 10-15 wt %. C13-NMR spectra are acquired on a Varian 400 NMR spectrometer at 100 MHz. Acquisition conditions were: 90° pulse angle; 10-20 seconds pulse delay; 2-3 second acquisition time; 8800 Hz sweep width; 125° C. probe temperature; nominally 5000 FIDs; and continuous Quantification was based on the resonance of the two αδ+ carbons and the one nBn methylene carbon, i.e., the three equivalent α-methylene carbons of a long chain branch at 34.69 ppm. The nearest neighboring signal, the αγ resonance of a BEB sequence at 34.71, is sufficiently small and well resolved from the LCB α-methylene signal with these materials that it does not interfere. ##STR1##

The assignment at 34.69 was confirmed by adding known amounts of Dowlex 2045 between 0.1 and 1.0 wt % to a number of the butene examples of the invention. Dowlex 2045 is an ethylene-octene copolymer which contains no long-chain branching, but does contain hexyl branches, the α-methylenes of which are indistinguishable from the α-methylenes of a long-chain branch. In each experiment, the magnitude of the signal at 34.69 corresponded to the amount of Dowlex added.

The polymers of the present invention have CDBI's generally in the range of greater than 50% to 99%, preferably in the range of 55% to 85%, and more preferably 60% to 80%, even more preferably greater than 60%, still even more preferably greater than 65%. Obviously, higher or lower CDBI's may be obtained using other catalyst systems with changes in the operating conditions of the process employed.

This polymers of this invention are distinguishable over LDPE, in that, for the purposes of this patent specification the polymers of the invention are substantially linear and not formed by a free radical polymerization process. The polymers of the invention are also distinguishable from known LLDPE polymers on the basis of their molecular weight distribution (MWD). The MWD of the present polymers is materially broader than that of LLDPE's produced using the same metallocene in an unsupported form in a solution or slurry polymerization process. The polydispersity index (M_(w) /M_(n)) of our polymers is typically in the range of 2.6-10, compared to a range of 2-3.5, typical for known metallocene LLDPE polymers. In this regard the present polymers are similar to many commercially available LLDPE polymers produced using conventional Ziegler-Natta catalysts. However, the tails of the molecular weight distribution curve for the present polymer are considerably smaller than those of known conventional Ziegler-Natta LLDPE's. This distinction is readily apparent by comparing the ratio of M_(z) /M_(w) (the ratio of the third moment to the second moment) and M_(z+1) /M_(w) (ratio of the fourth moment to the second moment). Utilizing the present invention, LLDPE polymers can be produced with an M_(z) /M_(w) less than 3.0, usually less than 2.5 and most typically in the range of 2-2.5. In contrast, the ratio of M_(z) /M_(w) for conventional Ziegler-Natta polymers is typically above 2.5. Table 4 provides further data regarding M_(z) and M_(w) for our polymers.

The polymers of this invention unexpectedly exhibit surprising melt strength properties, see Table 4. The melt strength of a polymer at a particular temperature, e.g., 190° C., can be determined with a Gottfert Rheotens Melt Strength Apparatus. The measurement is done by grasping the extrudate from a capillary rheometer, or from an extruder equipped with a capillary die, using variable speed gears and increasing the gear speed at a constant acceleration until the molten polymer strand breaks. The force in the strand is measured with a balance beam in conjunction with a linear variable displacement transducer. The force required to extend and then break the extrudate is defined as the melt strength.

The force is measured in centinewtons (cN). A typical plot of force vs. wheel velocity. Linear polymers frequently resonate immediately before the strand breaks. In such cases, the plateau force is approximated by the midline between the oscillations.

Typically the polymers of the invention have a melt strength in the range of about 3.0 centi-newton (cN) to about 20 cN, preferably greater than about 3.5 cN and most preferably greater than about 5.0 cN, even more preferably greater than 6 cN and still more preferably greater than 7 cN. The melt strength of the polymers of the invention are more than twice that of typical metallocene or conventional Ziegler-Natta made polymers. Typically the polymers of the present invention have melt strengths in the range of 2× to 4× that of typical metallocenes and conventional Ziegler-Natta produced polymers, the polymers of the invention are preferably greater than 2× and most preferably greater than 2.5×.

Film Properties

One of the processing disadvantages of LDPE's is their inability to be drawn down into thin gauges, e.g., less than 25.4μ(1 mil). Copolymers produced with metallocenes A and E, on the other hand, have substantially greater draw-down, as do typical linear polyethylenes. Gauges less than 12.7μ(0.5 mil) are easily achievable.

The films of this invention can be formed from the polymer of the invention by methods well known in the art. For example, forming operations include, film, sheet, and other fiber extrusion and co-extrusion as well as blow molding, injection molding and roto molding. Films include blown or cast films in monolayer or multilayer constructions formed by coextrusion or by lamination. The preferred forming operation for the film of the invention is a blown film operation.

For example, the polymers of the invention may be extruded in a molten state through a flat die and then cooled to form sheets or cast films. Alternatively, the polymers may be extruded in a molten state through an annular die and then blown and cooled to form a tubular film. The tubular film may be axially slit and unfolded to form a flat film. The films of the invention may be unoriented, uniaxially oriented or biaxially oriented.

The films of the invention may be single layer or multi-layer films. The multiple-layer films may consist of one or more layers formed from polymers of the invention. The films may also have one or more additional layers formed from other materials such as other polymers, LLDPE, LDPE, HDPE, PP, PB, EVA, polyester, EVOH and, for instance, metal foils, paper and the like.

Multiple-layer films may be formed by methods well known in the art. If all layers are polymers, the polymers may be coextruded through a coextrusion feedblock and die assembly to yield a film with two or more layers adhered together but differing in composition. Multiple-layer films may also be formed by extrusion coating whereby a substrate material is contacted with the hot molten polymer as the polymer exits the die. Extrusion coating is useful with substrates that are woven or knitted from natural or synthetic fibers or yarns, e.g., textiles, or substrates made from non-polymer materials such as glass, ceramic, paper or metal.

Multiple-layer films may also be formed by combining two or more single layer films prepared as described above. The two layers of a film so formed may be adhered together with an adhesive or by the application of heat and pressure.

The films of the invention are useful as shrink films, cling film, stretch film, sealing films, oriented films, snack packaging, heavy duty bags, grocery sacks, baked and frozen food packaging, medical packaging, industrial liners, membranes, etc. in food-contact and non-food contact application. Fiber forming operations include melt spinning, solution spinning and melt blown fiber operations. Such fibers may be used in woven or non-woven form to make filters, diaper fabrics, medical garments, geotextiles, etc. General extruded articles include medical tubing, wire and cable coatings, geomembranes, and pond liners. Molded articles include single and multi-layered constructions in the form of bottles, tanks, large hollow articles, rigid food containers, toys and the like.

The films of the invention can contain anti-oxidants, slip, anti-block, processing aids, pigments, UV inhibitors, anti-static agents, or other additives as required for the application with out substantially departing from the scope of our invention.

The polymers of the invention can also be employed in multi-layer films. In some applications they will be desirable as the skin layer in coextruded films to impart enhanced clarity, blocking resistance and cling performance to the final film. In other applications they will be used as the core layer, taking advantage of their toughness and puncture resistance.

While film is likely the single most important application for polymers of the invention, they have other uses. The polymers of the invention are useful in producing plastic sheeting, injection molding, rotomolding and other processes.

The polymer of the invention can be blended with additives and other ingredients known to those of ordinary skill in the art such as fillers, antioxidants, tackifiers, UV stabilizers, heat stabilizers, pigments, dyes, waxes, silica, talc and the like. It is also possible to add peroxides and other free radical generators to the inventive polymers in order to modify their Theological properties.

In addition, the polymers of the present invention can be modified by blending with other polymers. It is well known in the prior art to add various other polymers to LLDPE in order to obtain improved performance. For example, polymers can be added to improve the processing characteristics of the LLDPE and/or the properties of films made from the polymers. Such film properties may include stiffness, cling, clarity, gloss, adhesion to substrates, cutting characteristics, sealing characteristics, coefficient of friction, tensile strength, MD and TD tear strength, impact strength, puncture resistance, blocking tendency, surface characteristics, shrinkage characteristics, low temperature flexibility, gas and moisture permeability, other properties. Generally the property improvements represent increases in the level of the particular film property, but sometimes blending is done to achieve lower property levels, such as, for example, lower tear resistance in order to impart good openability to packages made from the films.

Polymers suitable for blending with the inventive polymers of the invention include, but are not limited to, polyolefins such as polypropylene and ethylene propylene copolymers, VLDPE, plastomers, LDPE, EVA, EMA, copolymers of acrylic acid, polymethylmethacrylate or any other polymers polymerizable by a high-pressure free radical process, PVC, polybutene-1, isotactic polybutene, ABS resins, elastomers such as ethylene-propylene rubber (EPR), vulcanized EPR, EPDM, block copolymer elastomers such as SBS and the like, nylons, polycarbonates, PET resins, crosslinked polyethylene, copolymers of ethylene and vinyl alcohol (EVOH), polymers of aromatic monomers such as polystyrene, poly-1 esters, high molecular weight HDPE, low molecular weight HDPE, graft copolymers generally, polyacrylonitrile homopolymer or copolymers, thermoplastic polyamides, polyacetal, polyvinylidine fluoride and other fluorinated elastomers, polyethylene glycols, polyisobutylene (PIB), hydrocarbon resins, terpene resins, and other tackifying polymers, and numerous others and combinations thereof.

Three distinctive features of films made with the subject copolymers relative to conventional Ziegler-Natta copolymers are their low extractables (and associated low reblock), their good clarity, and their unusual tensile properties at low elongation.

The low extractables from films made with these products is especially dramatic when compared to the extractables from hexene copolymer films made with conventional Ziegler-Natta catalysts at higher MI's (e.g., control #2). The broader MWD polymers of the invention made with metallocene A have a substantially lower extractable level than the conventional Ziegler-Natta made products. The preferred range of extractables for the film of the invention are in the range of 0.5% to 2.0%, preferably 0.5 to 1.6% and most preferably 0.5 to 1.4%.

EXAMPLES

In order to provide a better understanding of the invention including representative advantages thereof, the following examples are offered.

Examples 1-9 and 15-26 illustrate embodiments of this invention. Examples 10-14 are comparative. The designation of (1,2/1,3-MeEtCp)₂ ZrCl₂ is illustrative of the catalyst of the invention as previously described in this patent specification.

Example 1 Preparation of in-situ Mixture of Isomers of (MeEtCp)₂ ZrCl₂

Methylcyclopentadiene dimer was cracked to the monomeric units over high viscosity silicone oil. A sample of the freshly prepared methylcyclopentadiene (100.5 g, 1.26 mol) was diluted in 500 cm³ tetrahydrofuran in a 3-liter flask. The flask was cooled in ice-bath to 0° C. and 900 cm³ of 1.4 M solution of methyl-lithium in hexanes was added slowly. After complete addition of the MeLi, the ice-bath was removed and stirring continued for 3 hours at room temperature. Then the flask was cooled again to 0° C. and bromoethane (139.2 g, 1.28 mol) was added slowly as solution in THF. The mixture was then stirred for 15 hours. The resulting product was washed with distilled water and the organic layer was dried over sodium sulfate. This was then filtered and concentrated under vacuum and the concentrate was distilled with a gentle N₂ sparge; the fraction boiling between 118-120° C. was saved.

Freshly distilled methylethyl-cyclopentadiene isomers (41.9 g, 0.388 mol) as above was dissolved in 30 cm³ THF. 242 cm³ of 1.6 M solution of nBuLi in hexanes was slowly added to this and stirring continued for 3 hours after all the nBuLi had been added. This solution was then added slowly to a slurry of ZrCl₄ (45.2 g, 0.194 mol) in 200 cm³ THF at -80° C. Stirring continued for 15 hours as the temperature slowly warmed up to 20° C. The solvent was removed under vacuum and the solid recovered was extracted with toluene. The toluene extract was concentrated and pentane was added to aid precipitation of the pure compound at -30° C.

Preparation of Supported (MeEtCp)₂ ZrCl₂ Isomers

20 g of Davison 948 silica dried to 200° C. was slurried in 150 cm³ toluene in a reaction flask. The flask was cooled to 0° C. and 35 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.428 g (MeEtCp)₂ ZrCl₂ isomers as prepared above was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 140 and Zr loading of 0.35 wt %.

Polymerization Test

The silica supported catalyst as prepared above was tested for ethylene/1-butene copolymerization in a semi-batch gas-phase reactor at 85° C. The pressure in the reactor was held constant by continuously feeding 5 mol-% 1-butene in ethylene to compensate for any pressure change due to polymerization. After 0.5 hours, the polymer formed was separated from the seed bed material and analyzed for resin molecular properties shown in Table 1.

Example 2 Preparation of Supported (MeEtCp)₂ ZrCl₂ Isomers for Olefin Polymerization

10 g of Davison 948 silica dried to 200° C. was slurried in 150 cm³ toluene in a reaction flask. The flask was cooled to 0° C. and 35 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.478 g (MeEtCp)₂ ZrCl₂ isomers as prepared above was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.60 wt %. This catalyst was then tested for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 3 Preparation of Supported (MeEtCp)₂ ZrCl₂ Isomers for Olefin Polymerization

20 g of Davison 948 silica dried to 200° C. was slurried in 120 cm³ toluene in a reaction flask. The flask was cooled to 0° C. and 65 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 80° C. and maintained for 5 hours. Then a toluene solution of 0.966 g (MeEtCp)₂ ZrCl₂ isomers as prepared above was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.60 wt %. This catalyst was then tested for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 4 Preparation of Supported (MeEtCp)₂ ZrCl₂ Isomers for Olefin Polymerization

650 g of Davison 948 silica dried to 200° C. was slurried in 2500 cm³ toluene in a reaction flask. The flask was cooled to 0° C. and 1440 cm³ of 30 wt % methylalumoxane in toluene was added. After 3.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 25.5 g (MeEtCp)₂ ZrCl₂ isomers as prepared above was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 100 and Zr loading of 0.60 wt %. This catalyst was then tested for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 5 Preparation of Supported (MeEtCp)₂ ZrCl₂ Isomers for Olefin Polymerization

400 g of Davison 948 silica dried to 200° C. was slurried in 1500 cm³ toluene in a reaction flask. The flask was cooled to 0° C. and 800 cm³ of 30 wt % methylalumoxane in toluene was added. After 2 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 15.6 g (MeEtCp)₂ ZrCl₂ isomers as prepared above was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 90 and Zr loading of 0.60 wt %. This catalyst was then tested for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 6 Preparation of Supported (MeEtCp)₂ ZrCl₂ Isomers for Olefin Polymerization

10 g of Davison 948 silica dried to 200° C. was slurried in 150 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 28 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.42 g (MeEtCp)₂ ZrCl₂ isomers as prepared above was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 100 and Zr loading of 0.60 wt %. This catalyst was then tested for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 7 Preparation of in-situ Mixture of Isomers of (Me^(n) PrCp)₂ ZrCl₂

The procedure described in Example 1 was adopted except that after the freshly-prepared methylcyclopentadiene was lithiated, 1-bromopropane was used and the subsequent work and conditions were the same.

Preparation of Supported Isomers (Me^(n) PrCp)₂ ZrCl₂

28 g of Davison 948 silica dried to 200° C. was slurried in 300 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 75 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 1.2 g (Me^(n) PrCp)₂ ZrCl₂ isomers as prepared above was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.55 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 8 Preparation of in-situ Mixture of Isomers of (Me^(n) BuCp)₂ ZrCl₂

The procedure described in Example 1 was adopted except that after the freshly-prepared methylcyclopentadiene was lithiated, 1-bromobutane was used and the subsequent work and conditions were the same.

Preparation of Supported Isomers (Me^(n) BuCp)₂ ZrCl₂

20 g of Davison 948 silica dried to 200° C. was slurried in 250 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 42 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.671 g (Me^(n) BuCp)₂ ZrCl₂ isomers as prepared above was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.45 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 9 Preparation of in-situ Mixture of Isomers of (Me^(i) BuCp)₂ ZrCl₂

1-Bromo-2-methylpropane (276 g, 2.01 mol) was sampled into a 2-liter flask and cooled to 0° C. 1000 cm³ of a 2.0 M solution of sodium cyclopentadienide in THF was added slowly and then stirring was continued for 15 hours. The product was extracted from the sodium by-product and distilled under N₂ at 120° C.

The freshly distilled ^(i) BuCp (108 g, 0.885 mol) from above was weighed into a 1-liter flask and 400 cm³ THF was added. The flask was cooled to 0° C. and 356 cm³ of 2.5 M solution of n-BuLi in hexanes was added slowly. Stirring was continued for 2 more hours after all the n-BuLi had been added. Then the flask was cooled to -78° C. and 125.8 g of methyl iodide in 75 cm³ THF was added slowly. The reaction was allowed to stir for 15 hours. Then the Me^(i) BuCp product was extracted from the LiI by-product and distilled under N₂.

A sample of the freshly distilled Me^(i) BuCp (78.4 g, 0.576 mol) from above was weighed into a 1-liter reaction flask and the flask was cooled to 0° C. 360 cm³ of a 1.6 M solution of n-BuLi in hexanes was added slowly. After 3 hours, the resulting solution was added slowly to a suspension of ZrCl₄ (67.14 g, 0.288 mol) in THF at -78° C. The reaction slowly warmed up to room temperature for 15 hours. The solvent was removed and the crude product was extracted with toluene/pentane.

Preparation of Supported (Me^(i) BuCp)₂ ZrCl₂ Isomers

20 g of Davison 948 silica dried to 200° C. was slurried in 200 cm³ toluene in a reaction flask. The flask was cooled to 0° C. and 65 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 1.11 g (Me^(i) BuCp)₂ ZrCl₂ isomers as prepared above was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.60 wt %. This catalyst was then tested for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 10 Preparation of (1,3-MeEtCp)₂ ZrCl₂

1,3-Methylethylcyclopentadiene (12.5 g, 0.116 mol) was weighed into a reaction flask and 60 cm³ THF was added. The flask was cooled to 0° C. and 73 cm³ of a 1.6 M solution of n-BuLi in hexane was added slowly. The reaction was allowed to continue for an additional 3 hours after all the n-BuLi had been added. The resulting solution was then added slowly to a suspension of ZrCl₄ (13.52 g, 0.058 mol) in THF at -78° C. The reaction slowly warmed up to room temperature for 15 hours. The solvent was removed and the crude product was extracted with toluene/pentane.

Preparation of Supported (1,3-MeEtCp)₂ ZrCl₂

52.3 g of Davison 948 silica dried to 200° C. was slurried in 300 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 105 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 1.521 g (1,3-MeEtCp)₂ ZrCl₂ as prepared above was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.45 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 11 Preparation of Supported (^(n) PrCp)₂ ZrCl₂

1200 cm³ of a 30 wt % MAO solution in toluene was added to 680 g of Davison 948 silica dried to 200° C. in a 2-gal reactor. Then 2000 cm³ toluene was added. The temperature was raised to 70° C. and maintained for 4 hours. Then a toluene solution of 16.5 g (^(n) PrCp)₂ ZrCl₂ was added slowly followed by a 2 hours hold of the reaction conditions. The resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 130 and Zr loading of 0.4 wt %. A sample of this catalyst was tested for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 12 Preparation of Supported (1,3-Me^(n) BuCp)₂ ZrCl₂

20.6 g of Davison 948 silica dried to 200° C. was slurried in 110 cm³ toluene in a reaction flask. The flask was cooled to 0° C. and 36.5 cm³ of 30 wt % methylalumoxane in toluene was added. After 1 hour, the temperature was raised to 70° C. and maintained for 4 hours. Then a toluene solution of 0.742 g (1,3-Me^(n) BuCp)₂ ZrCl₂ as prepared above was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 100 and Zr loading of 0.5 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 13 Preparation of Supported (1,2-Me^(n) BuCp)₂ ZrCl₂

20 g of Davison 948 silica dried to 200° C. was slurried in 250 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 42 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3.5 hours. Then a toluene solution of 0.685 g (1,2-Me^(n) BuCp)₂ ZrCl₂ as prepared above was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.45 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 14 Preparation of Supported {(1,3-Me^(n) BuCp)₂ ZrCl₂ /(1,2-Me^(n) BuCp)₂ ZrCl₂ }

20.9 g of Davison 948 silica dried to 200° C. was slurried in 250 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 46 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.35 g (1,3-Me^(n) BuCp)₂ ZrCl₂ mixed with 0.35 g (1,2-Me^(n) BuCp)₂ ZrCl₂ was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.45 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 1.

Example 15 Preparation of Supported {(1,2/1,3-MeEtCp)₂ ZrCl₂ /(^(n) PrCp)₂ ZrCl₂ }

20 g of Davison 948 silica dried to 200° C. was slurried in 200 cm³ toluene in a reaction flask. The flask was cooled to 0° C. and 55 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70 ° C. and maintained for 3 hours. Then a toluene solution of 0.445 g (1,2/1,3-MeEtCp)₂ ZrCl₂ mixed with 0.445 g (^(n) PrCp)₂ ZrCl₂ was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 110 and Zr loading of 0.60 wt %. This catalyst was then tested for 0.5 hours for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2.

Example 16 Preparation of Supported {(1,2/1,3-MeEtCp)₂ ZrCl₂ /(^(n) PrCp)₂ ZrCl₂ }

590 g of Davison 948 silica dried to 200° C. was slurried in 3000 cm³ heptane in a reaction vessel. The temperature was reduced to 0° C. and 1400 cm³ of 30 wt % methylalumoxane in toluene was added. The temperature was then raised to 70° C. and maintained for 4 hours. Then a toluene solution of 18.55 g (1,2/1,3-MeEtCp)₂ ZrCl₂ mixed with 6.18 g (^(n) PrCp)₂ ZrCl₂ was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 100 and Zr loading of 0.60 wt %. A sample of this catalyst was then tested for 0.5 hours for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2.

Example 17

A sample of this catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2. The copolymer has a CDBI of 67%.

Example 18 Preparation of Supported {(1,2/1,3-MeEtCp)₂ ZrCl₂ /(1,2/1,3-Me^(n) PrCp)₂ ZrCl₂ }

10 g of Davison 948 silica dried to 200° C. was slurried in 200 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 21 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.147 g (1,2/1,3-Me^(n) PrCp)₂ ZrCl₂ mixed with 0.136 g (1,2/1,3-MeEtCp)₂ ZrCl₂ was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 135 and Zr loading of 0.41 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2.

Example 19 Preparation of Supported {(1,2/1,3-MeEtCp)₂ ZrCl₂ /(1,3-Me^(n) BuCp)₂ ZrCl₂ }

20 g of Davison 948 silica dried to 200° C. was slurried in 250 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 34 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.264 g (1,3-Me^(n) BuCp)₂ ZrCl₂ mixed with 0.237 g (1,2/1,3-MeEtCp)₂ ZrCl₂ was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 140 and Zr loading of 0.35 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2.

Example 20 Preparation of Supported {(1,2/1,3-MeEtCp)₂ ZrCl₂ /(1,3-Me^(n) BuCp)₂ ZrCl₂ }

20 g of Davison 948 silica dried to 200° C. was slurried in 200 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 47 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.231 g (1,3-Me^(n) BuCp)₂ ZrCl₂ mixed with 0.603 g (1,2/1,3-MeEtCp)₂ ZrCl₂ was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 100 and Zr loading of 0.60 wt %. This catalyst was then tested for 0.5 hours for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2.

Example 21 Preparation of Supported {(1,2/1,3-MeEtCp)₂ ZrCl₂ /(1,3-Me^(n) BuCp)₂ ZrCl₂ }

30 g of Davison 948 silica dried to 200° C. was slurried in 250 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 59 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 4 hours. Then a toluene solution of 0.826 g (1,3-Me^(n) BuCp)₂ ZrCl₂ mixed with 0.180 g (1,2/1,3-MeEtCp)₂ ZrCl₂ was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.45 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2.

Example 22 Preparation of Supported {(1,2/1,3-MeEtCp)₂ ZrCl₂ /(1,2/1,3-Me^(n) BuCp)₂ ZrCl₂ }

20.2 g of Davison 948 silica dried to 200° C. was slurried in 250 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 40 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70 ° C. and maintained for 3 hours. Then a toluene solution of 0.359 g (1,2/1,3-Me^(n) BuCp)₂ ZrCl₂ mixed with 0.312 g (1,2/1,3-MeEtCp)₂ ZrCl₂ was added slowly followed by a 2 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 120 and Zr loading of 0.45 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2.

Example 23 Preparation of Supported {(1,2/1,3-MeEtCp)₂ ZrCl₂ /(1,2/1,3-Me^(i) BuCp)₂ ZrCl₂ }

10 g of Davison 948 silica dried to 200° C. was slurried in 200 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 20 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.210 g (1,2/1,3-Me^(i) BuCp)₂ ZrCl₂ mixed with 0.190 g (1,2/1,3-MeEtCp)₂ ZrCl₂ was added slowly followed by a 1 hour hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 93 and Zr loading of 0.57 wt %. This catalyst was then tested for 0.5 hours for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2.

Example 24 Preparation of Supported {(1,2/1,3-MeEtCp)₂ ZrCl₂ /(1,3-MeEtCp)₂ ZrCl₂ /(1,2/1,3-Me^(n) PrCp)₂ ZrCl₂ }

30 g of Davison 948 silica dried to 200° C. was slurried in 250 cm³ heptane in a reaction flask. The flask was cooled to 0° C. and 52 cm³ of 30 wt % methylalumoxane in toluene was added. After 0.5 hours, the temperature was raised to 70° C. and maintained for 3 hours. Then a toluene solution of 0.297 g (1,2/1,3-MeEtCp)₂ ZrCl₂ mixed with 0.223 g (1,3-MeEtCp)₂ ZrCl₂ and 0.240 g (1,2/1,3-Me^(n) PrCp)₂ ZrCl₂, was added slowly followed by a 1.5 hours hold of the reaction conditions. Then the resultant catalyst was dried to free-flowing powder under reduced pressure. This catalyst had Al/Zr molar ratio of 125 and Zr loading of 0.40 wt %. This catalyst was then tested for 1 hour for ethylene/1-butene copolymerization as described in Example 1; the results are summarized in Table 2.

Comparative Example 53

Comparative example 53 is linear ethylene-hexene copolymer produced in a gas phase process with a silica-supported, (^(n) BuCp)₂ ZrCl₂ /methyl alumoxane catalyst. MI, density, and melt flow ratio are 3.23, 0.931, and 17, respectively.

Comparative Example 54

Comparative example 54 is linear ethylene-hexene copolymer produced in a gas phase process with a silica-supported, (^(n) BuCp)₂ ZrCl₂ /methyl alumoxane catalyst. MI, density, and melt flow ratio are 1.91, 0.918, and 16, respectively.

Example 69

Example 69 is ethylene-hexene copolymer produced in a gas-phase reactor with a silica-supported, (iPrCp)₂ ZrCl₂ /methyl alumoxane catalyst. MI and density are 1.39 and 0.918, respectively.

Table 4 includes the two key GPC moments (Mw and Mz) for each example from each category, plus some key distinctions between the product families. Note that the high molecular weight component of the invention, reflected by its Mz, is less than the Ziegler-Natta products at equivalent MI, and that the high melt strength butene copolymer examples of the invention essentially contains no detectable long-chain branching.

                                      TABLE 1                                      __________________________________________________________________________     METALLOCENE CATALYSTS BASED ON MIXTURE OF ISOMERS                                                      Polymer Molecular Properties                                             Catalyst   I.sub.2           Zr  Al/Zr                                                                              Temp.                     Example Metallocene Activity (.sup.1) Density (I.sub.21) I.sub.21                                                                       /I.sub.2                                                                       M.sub.w                                                                        M.sub.w                                                                        /M.sub.n wt %                                                                  molar °                                                                 C. Note             __________________________________________________________________________     1     (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2                                                          1015  0.9318                                                                              1.1 38.7                                                                               96200                                                                               5.2  0.35                                                                               140 70  2                     2 " 848 0.9286 0.4 36.5 117100 6.2 0.60 120 70 2                               3 " 937 0.9264 1.3 46.5 93000 4.3 0.60 120 80 2                                4 " 859 0.9296 0.6 32.9 106500 5.1 0.60 100 70 2                               5 " 864 0.9302 0.4 41.3 115100 6.0 0.60  90 70 2                               6 " 1269 0.9304 0.2 43.3 120000 6.2 0.60 100 70 3                              7 (1,2/1,3-Me.sup.n PrCp).sub.2 ZrCl.sub.2 1929 0.9161 3.6 21.2 79300                                                                   3.6 0.55 120                                                                   70 3                  8 (1,2/1,3-Me.sup.n BuCp).sub.2 ZrCl.sub.2 2155 0.9151 4.6 21.4 71100                                                                   3.4 0.45 120                                                                   70 3                  9 (1,2/1,3-Me.sup.i BuCp).sub.2 ZrCl.sub.2 1135 0.9402 6.0 22.4 62800                                                                   3.4 0.60 120                                                                   70 2                  10  (1,3-MeEtCp).sub.2 ZrCl.sub.2 874 0.9155 (7.1) -- 127900 2.7 0.45                                                                   120 70 3                                                                        11  (.sup.n                                                                   PrCp).sub.2                                                                    ZrCl.sub.2                                                                     2929 0.9465                                                                    5.3 23.2 61500                                                                 3.3 0.40 120                                                                   70 2                  12  (1,3-Me.sup.n BuCp).sub.2 ZrCl.sub.2 1837 0.9162 1.0 17.9 103000                                                                    2.5 0.50 100                                                                   70 2                  13  (1,2-Me.sup.n BuCp).sub.2 ZrCl.sub.2 1880 0.9195 5.1 18.2 69600 3.7                                                                 0.45 120 70 3                                                                   14  (1,2-Me.su                                                                p.n BuCp).sub.2                                                                 ZrCl.sub.2 +                                                                  2326 0.9126                                                                    3.5 19.6 77300                                                                 3.1 0.45 120                                                                   70 3,4                                                                           (1,3-Me.sup.n                                                                 BuCp).sub.2                                                                   ZrCl.sub.2          __________________________________________________________________________      (1) g.sub.PE /(g.sub.CAT * hours * 150 psi)                                    (2) Toluene used as solvent                                                    (3) Heptane used as solvent                                                    (4) 1:1 mixture of the 2 compounds                                       

                                      TABLE 2                                      __________________________________________________________________________     MIXED-METALLOCENE CATALYSTS BASED ON MIXTURE OF ISOMERS                                                       Polymer Molecular                                 Metallocene Ratio of Catalyst Properties Zr                                  Example                                                                             Combination   Components                                                                           Activity (.sup.1)                                                                    Density                                                                            I.sub.2                                                                           I.sub.21 /I.sub.2                                                                 wt %                                  __________________________________________________________________________     15   (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 +                                                          50:50 1978  0.9201                                                                             1.8                                                                               21.9                                                                              0.60                                     (.sup.n PrCp).sub.2 ZrCl.sub.2                                                16 (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 + 75:25 1027 0.9278 2.0 26.6 0.60                                                  (.sup.n PrCp).sub.2 ZrCl.sub.2        17 (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 + 75:25 1258 0.9155 2.5 24.9 0.60                                                  (.sup.n PrCp).sub.2 ZrCl.sub.2        18 (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 + 50:50 1354 0.9196 1.7 24.3 0.41                                                  (1,2/1,3-Me.sup.n PrCp).sub.2                                                ZrCl.sub.2                              19 (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 + 50:50 1564 0.9104 1.2 21.9 0.35                                                  (1,3-Me.sup.n BuCp).sub.2                                                    ZrCl.sub.2                              20 (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 + 75:25 1132 0.9283 1.2 29.3 0.60                                                  (1,3-Me.sup.n BuCp).sub.2                                                    ZrCl.sub.2                              21 (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 + 20:80 1867 0.9165 2.2 21.9 0.45                                                  (1,3-Me.sup.n BuCp).sub.2                                                    ZrCl.sub.2                              22 (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 + 50:50 1411 0.9189 3.8 21.2 0.45                                                  (1,2/1,3-Me.sup.n BuCp).sub.2                                                ZrCl.sub.2                              23 (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 + 50:50 1274 0.9290 3.4 26.3 0.56                                                  (1,2/1,3-Me.sup.i BuCp).sub.2                                                ZrCl.sub.2                              24 (1,2/1,3-MeEtCp).sub.2 ZrCl.sub.2 + (1,3- 40:30:30  660 0.9181 0.3                                                 28.5 0.40                                MeEtCp).sub.2 ZrCl.sub.2 + (1,2/1,3-                                           Me.sup.n PrCp).sub.2 ZrCl.sub.2                                             __________________________________________________________________________      (1) g.sub.PE /(g.sub.CAT * hours * 150 psi)                              

                                      TABLE 4                                      __________________________________________________________________________                  Melt                                                                 MI MIR Strength                                                               Example dg/min (I.sub.21 /I.sub.2) (cN) Mn Mw Mz Mw/Mn Mz/Mw                 __________________________________________________________________________     53   3.23                                                                               17.2                                                                               2.0 33300                                                                              78700                                                                              137000                                                                              2.36                                                                               1.74                                           54 1.91 15.8 2.6 38850 89800 154000 2.31 1.72                                  69 1.39 -- 9.4 12870 103000 409800 8.00 3.98                                 __________________________________________________________________________

Polymerization Examples 100-103

Examples 100-103 were conducted with the following general polymerization procedure. A nitrogen filled 2 liter stirred autoclave was first treated with 0.15 ml of a triethyl aluminum in heptane containing 0.03 mmoles of aluminum to remove potential catalyst poisons. 800 ml of isobutane was charged to the autoclave. The temperature of the autoclave was raised to 185° F. (85° C.) with stirring giving a total pressure of 215 psig. Ethylene was then injected to raise the pressure to 335 psig. At this point, 100 mg of the supported catalyst slurried in a small amount of hexane was injected in one shot by an overpressure of ethylene. The ethylene supply valve remained open to maintain a constant 335 psig reactor pressure while monitoring the progress of the reaction from the ethylene flow rate over a period of about 40 minutes. The specific reactor conditions of each example are outlined below in table 5.

Polymerization Examples 104-106

Examples 104-106 were conducted with the following general polymerization procedure. A nitrogen filled 2 liter stirred autoclave was first treated with 0.15 ml of a triethyl aluminum in heptane containing 0.03 mmoles of aluminum to remove potential catalyst poisons. 90 ml fresh, dry butene having not been used in a polymerization process was charged to the autoclave followed by the addition of 800 ml of isobutane. The temperature of the autoclave was raised to 150° F. (65.6° C.) with stirring giving a total pressure of 140 psig. Ethylene was then injected to raise the pressure to 260 psig. At this point, 100 mg of the supported catalyst slurried in a small amount of hexane was injected in one shot by an overpressure of ethylene. The ethylene supply valve remained open to maintain a constant 260 psig reactor pressure while monitoring the progress of the reaction from the ethylene flow rate over a period of about 40 minutes. The specific reactor conditions of each example are outlined below in table 5.

Polymerization Examples 107-112

Examples 107-112 were conducted with the following general polymerization procedure. A nitrogen filled 2 liter stirred autoclave was first treated with 0.15ml of a triethyl aluminum in heptane containing 0.03 mmoles of aluminum to remove potential catalyst poisons. An amount of fresh, dry hexene-1 having not been used in a polymerization process was charged to the autoclave followed by the addition of 800 ml of isobutane. Table 6 shows the amount of hexene for each example The temperature of the autoclave was raised to 150° F. (65.6° C) with stirring giving a total pressure of 125 psig (862 kPa). Ethylene was then injected to raise the pressure to: 245 psig for examples 107 and 110; 215 psig for examples 108 and 111; and 185 psig for examples 109 and 112. At this point, 100 mg of supported catalyst slurried in a small amount of hexane was injected in one shot by an overpressure of ethylene. The ethylene supply valve remained open to maintain a constant reactor pressure while monitoring the progress of the reaction from the ethylene flow rate over a period of about 40 minutes. The constant reactor pressure was: 245 psig for examples 107 and 110; 215 psig for examples 108 and 111; and 185 psig for examples 109 and 112. The specific reactor conditions of each example are outlined below in table

Polymerization Examples 113-116

Examples 113-116 were conducted with the following general polymerization procedure. A nitrogen filled 2 liter stirred autoclave was first treated with 0.15 ml of a triethyl aluminum in heptane containing 0.03 mmoles of aluminum to remove potential catalyst poisons. 800 ml of isobutane was charged to the autoclave. The temperature of the autoclave was raised to 185° .F (85° C.) with stirring giving a total pressure of 215 psig. Ethylene was then injected to raise the pressure to 335 psig. At this point, 100 mg of the supported catalyst slurried in a small amount of hexane was injected in one shot by an overpressure of ethylene. The ethylene supply valve remained open to maintain a constant 335 psig reactor pressure while monitoring the progress of the reaction from the ethylene flow rate over a period of about 40 minutes. The specific reactor conditions of each example are outline below in table 7.

                                      TABLE 5                                      __________________________________________________________________________                                                    Cata-                                   lyst                                                                           Act-                                                                           iv-                                                                      Bu- Reactor Reactor Pressure Rxn Catalyst PE ity                             Ex.         Polymer                                                                              tene                                                                              Temp. IsoC.sup.= .sub.4                                                                  C.sup.= .sub.2                                                                    Total                                                                             Time                                                                              Charge                                                                             Yield                                                                             g/g/                                                                              Density                      #  Catalyst Type  Cc ° C.                                                                       ° F.                                                                       psig                                                                               psig                                                                              psig                                                                              Mins.                                                                             g   g  hr.                                                                               g/cc                                                                               I.sub.2                                                                           I.sub.21                                                                          MIR                __________________________________________________________________________     100                                                                               (1,3MeBuCp).sub.2 ZrCl.sub.2                                                            Homo- 0  85 185                                                                               215 120                                                                               335                                                                               40 0.10                                                                               30 450                                                                               0.9484                                                                             0.13                                                                              2.58                                                                              19.8                   Polyethylene                                                                 101 (1,3MeBuCp).sub.2 ZrCl.sub.2 Homo- 0 85 185 215 120 335 40 0.10 30                                                                   450 n/a n/a                                                                    n/a --                                                                            Polyethylen                                                                 e                    102 (n-PrCp).sub.2 ZrCl.sub.2 Homo- 0 85 185 215 120 335 40 0.10 140                                                                     2100 0.9480                                                                    1.03 16.72                                                                     16.2                   Polyethylene                                                                 103 (n-PrCp).sub.2 ZrCl.sub.2 Homo- 0 85 185 215 120 335 40 0.10 135                                                                     2025 n/a n/a                                                                   n/a --                                                                            Polyethylen                                                                 e                    104 (1,3MeBuCp).sub.2 ZrCl.sub.2 Butene 90 65 149 140 120 260 40 0.05                                                                    61 1830                                                                        0.8987 0.08                                                                    1.44 18.0                                                                         Plastomer                                                                    105 (n-PrCp).                                                                 sub.2                                                                          ZrCl.sub.2                                                                     Butene 90 65                                                                   149 140 120                                                                    260 40 0.05                                                                    239 7170                                                                       0.8995 0.73                                                                    11.95 16.4                                                                        Plastomer                                                                    106 (n-PrCp).                                                                 sub.2                                                                          ZrCl.sub.2                                                                     Butene 75 65                                                                   149 145 120                                                                    265 40 0.05                                                                    227 6810                                                                       0.9031 0.92                                                                    16.1 17.5                                                                         Plastomer       __________________________________________________________________________

                                      TABLE 6                                      __________________________________________________________________________                 CAT.                                                                              COM. C.sup.= .sub.6 in Liq.                                                                C.sup.= .sub.2 in Liq.                                                                     C.sup.= .sub.6 /C.sup.= .sub.2                                                         Prod.                           Ex.         wt.         Mole        Mole                                                                              mole wt.                                                                            Yield                                                                             G/g/                                                                              Den.                           # Catalyst mg cc mole wt. % wt. % Psig mole wt. % wt. % % in Liq. Gms                                                                    hr. gm/cc                                                                      I.sub.2                                                                        I.sub.21           __________________________________________________________________________                                                                 MIR                107                                                                               (n-PrCp).sub.2 ZrCl.sub.2                                                                50                                                                               135                                                                               1.076                                                                             15.92                                                                             11.22                                                                             120                                                                               1.585                                                                             6.23                                                                              12.75                                                                             0.888                                                                               217                                                                               6517                                                                              0.5996                                                                             0.55                                                                              10.3                                                                              18.7                 108 (n-PrCp).sub.2 ZrCl.sub.2  50 93 0.742 11.76 8.37 90 1.166 4.78                                                                      9.51 0.855                                                                     122 3664                                                                       0.5981 0.4                                                                     8.66 21.7                                                                       109 (n-PrCp).                                                                 sub.2                                                                          ZrCl.sub.2                                                                     50 53 0.423                                                                    7.19 5.17 60                                                                   0.755 3.23                                                                     6.65 0.777 30                                                                  900 0.8979                                                                     0.38 7.94                                                                      20.9                 110 (1,3MeBuCp).sub.2 ZrCl.sub.2 100 135 1.076 15.92 11.22 120 1.585                                                                     6.23 12.75                                                                     0.888 91 1366                                                                  0.9009 0.07                                                                     111 (1,3MeBnC                                                                 p).sub.2                                                                       ZrCl.sub.2                                                                     100 93 0.742                                                                   11.76 8.37 90                                                                  1.166 4.78                                                                     9.81 0.855 40                                                                  601 0.9011                                                                     0.09                 112 (1,3MeBuCp).sub.2 ZrCl.sub.2 100 53 0.423 7.19 5.17 60 0.755 3.23                                                                    6.65 0.777 10                                                                  150 0.9065                                                                     0.95               __________________________________________________________________________

                                      TABLE 7                                      __________________________________________________________________________                 Reactor                                                                            Rxn                                                                               Catalyst                                                                           PE Catalyst                                                 Temp. Time Charge Yield Activity                                             Ex # Catalyst ° C. mins. g g g/g/hr. I.sub.2 I.sub.21 MIR             __________________________________________________________________________     113                                                                               (n-PrCp).sub.2 ZrCl.sub.2                                                               85  40 0.10                                                                               135                                                                               2025                                                                               0.82                                                                              14.1                                                                              17.2                                         114 (1,3MeBuCp).sub.2 ZrCl.sub.2 85 40 0.10 29.5 442.5 0.15 3.0 20.0                                              115 (n-BuCp).sub.2 ZrCl.sub.2 85 40                                           0.10 84 1260 0.92 16.8 18.3                  116 (n-BuCp).sub.2 ZrCl.sub.2 85 40 0.10 81 1215 0.96 15.6 16.3              __________________________________________________________________________

While the present invention has been described and illustrated by reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to variations not necessarily illustrated herein. For example, it is not beyond the scope of this invention to mix at least two of the catalysts of this invention or mix the catalyst of this invention with any other metallocene catalyst. For this reason, then, reference should be made solely to the appended claims for purposes of determining the true scope of the present invention. 

We claim:
 1. A process for producing polymers, comprising:a) selecting as polymerizable monomers ethylene, either alone or in combination with one or more alpha-olefins and, optionally, a polyene; b) conducting a polymerization of said polymerizable monomers in a slurry, or gas phase process, wherein said polymerization utilizes a catalyst system comprising a support material and a catalytic complex formed by activating (n-PrCp)₂ ZrCl₂ to a catalytic state.
 2. The process of claim 1 wherein said polymerization is conducted in a gas phase process.
 3. The process of claim 1 wherein said polymerization is conducted in a slurry phase process.
 4. The process of claim 1 wherein said active catalytic complex is formed by activation with an alumoxane, an ionic activator, or a combination thereof.
 5. The process of claim 4 wherein said active catalytic complex is formed by activation with an alumoxane.
 6. The process of claim 1 wherein said support material is silica.
 7. The process of claim 1 comprising selecting as polymerizable monomers ethylene alone.
 8. The process of claim 7 wherein 1-butene is selected as an additional polymerizable monomer.
 9. The process of claim 7 wherein 1-hexene is selected as an additional polymerizable monomer.
 10. The process of claim 7 wherein 1-octene is selected as an additional polymerizable monomer. 